Modular Cylindrical Battery Pack Assembly With CCS Cooling
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Solution Overview
Problem
The existing cylindrical cell CTP structure in power batteries faces challenges such as a complex grouping process, difficulty in filling the entire pack with glue, and difficulty in repair due to the large number of single cylindrical cells.
Innovation Solution
A battery module design comprising a casing, fixed bracket, cell stack, cell contact system (CCS) component, and cooling plate, with features like thermally-conductive structural glue, potting glue, and exhaust channels to simplify the assembly process, improve positioning, and enhance safety and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple cylindrical cells are directly connected in series and parallel to form a CTP structure, then the battery pack capacity increases, but the grouping process becomes complex and glue filling becomes difficult
Solution Approach 1:
The patent divides the battery pack into multiple independent battery modules, each containing a small number of cylindrical cells (3-9 cells). Each module is assembled independently with simplified grouping processes, then multiple modules are connected to achieve the required total capacity. This segmentation transforms the complex task of grouping many cells directly into multiple simple grouping tasks for small cell groups.
2Quantity of substance
If multiple cylindrical cells are directly connected in series and parallel to form a CTP structure, then the battery pack capacity increases, but the glue filling process becomes difficult
Solution Approach 1:
The battery pack is segmented into multiple independent modules, each containing only 3-9 cylindrical cells. The glue filling process is performed separately for each small module rather than attempting to fill the entire large battery pack at once. This segmentation makes the glue filling process much easier to control and execute, ensuring proper filling without the difficulties associated with large-scale single-step filling.
3Reliability
If a single cylindrical cell has quality problems in the CTP structure, then the entire battery pack needs to be disassembled for repair
Solution Approach 1:
The battery pack is divided into multiple independent battery modules, each containing a small number of cylindrical cells. When a quality problem occurs in a single cell, only the affected module needs to be disassembled and repaired, while other modules remain intact. This segmentation transforms the repair task from disassembling the entire battery pack to disassembling only one small module, significantly improving repair convenience.
4Productivity
If cylindrical cells are arranged in groups to form a cell group, then the battery pack structure is formed, but positioning accuracy becomes difficult to control
Solution Approach 1:
The patent employs a fixed bracket with pre-designed positioning slots that are manufactured in advance with precise dimensions and locations. Before assembling the cylindrical cells, the positioning slots are already prepared in the fixed bracket. When cells are installed, they are simply placed into these pre-prepared slots, which automatically ensure accurate positioning without requiring complex adjustment operations during assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for simplified assembly, improved safety through exhaust channels, enhanced heat dissipation, and convenient maintenance by enabling repair of individual modules, reducing the complexity of glue filling and positioning issues.
Implementation Method 1
a thermally-conductive structural glue is further included, and the thermally-conductive structural glue is filled at least in a space between the top portions of the cylindrical cells and the cooling plate
Implementation Method 2
exhaust channels are formed between the fixed bracket and the bottom plate, at least one of the two end plates is provided with an exhaust groove, and the exhaust groove communicates with the exhaust channels
Data Source
AI summary
A battery module and a battery pack are provided. The battery module includes a casing including a bottom plate, side plates, end plates, and a top plate fixedly connected to the side plates and the end plates to enclose and form an accommodating cavity; a fixed bracket located in the accommodation cavity, mounted on the bottom plate, and provided with a plurality of rows of positioning slots; a cell stack including cylindrical cells arranged in a plurality of rows, where a top portion of each of the cylindrical cells is provided with an electrode terminal; a cell contact system (CCS) component mounted on one side of the cell stack close to the top plate and electrically connected to the electrode terminals of the cylindrical cells; and a cooling plate arranged on one side of the CCS component away from the cell stack.